Panel for forming a floor covering and method for manufacturing such panels

ABSTRACT

Panel for forming a floor covering, where this panel has at least two layers of thermoplastic material, where the two layers substantially have a strewn and pressed granulate, where the respective layers enclose a glass fiber layer.

This invention relates to panels for forming a floor covering and to amethod for manufacturing such panels.

More particularly, the invention relates to panels comprising at least alayer, more particularly a substrate layer, of thermoplastic material.Further, such panels may also comprise, above said layer, at least a toplayer with a printed decor and a translucent or transparent wear layer.

In particular, the present invention relates to panels of the typewhich, on two or more opposite edges, comprises coupling means orcoupling parts with which two of such floor panels can be coupled atsaid edges in such a manner that they are mutually locked in ahorizontal direction perpendicular to the respective edge and in theplane of the floor panels, as well as in a vertical directionperpendicular to the plane of the floor panels. Such floor panels can beapplied for composing a so-called floating floor covering, wherein thefloor panels are connected to each other at their edges, however, liefreely on the underlying surface.

Such panels are known, for example, from EP 1 938 963, EP 2 339 092 A1and WO 2010/023042. From these documents, more particularly vinyl-basedfloor panels are known for forming a floating floor covering. Suchvinyl-based floor panels mostly have a thickness of 3 to 5 millimetersand have a high material density. The respective core of the panels iscomposed of one or more prefabricated layers of thermoplastic material,for example, soft PVC. Above the print, a transparent thermoplasticlayer and possibly a superficial layer of lacquer are provided. Thevarious layers are adhered to each other by means of a thermallamination process. According to EP 2 339 092 A1, a reinforcing layer onthe basis of glass fiber can be applied.

The panels of the state of the art show the disadvantage that they arestrongly subjected to shrinkage and expansion, or even bending, underthe influence of temperature. Shrinkage and expansion may lead to thatthe floor covering or the individual panels are pushed upward, and, forexample, to a mutual release of the coupling parts, or to the phenomenonthat the individual panel-shaped elements will drift apart, whereby gapsmay occur. The features of the panels of the state of the art are suchthat problems may occur already with warming due to incident sunlight,for example, at a window in a room.

From WO 2012/004701, it is known to apply a glass fiber layer orembedded profiles for increasing the dimensional stability of suchpanels. In particular, here the bending stiffness of the panels has beentackled.

U.S. Pat. No. 6,306,318 describes a method for recycling discardedcarpets, wherein, starting from a molten mixture of a recyclate on thebasis of discarded carpets and fresh soft PVC, flexible floor tileshaving a minimum thickness of 5 millimeters are produced by means of aninjection molding process. As an alternative for the recyclate ofdiscarded carpets, also recyclate of glass fiber-reinforced syntheticmaterial (English: fiberglass) can be applied. The obtained tile isrelatively hard and the flexibility leaves much to be desired. This maylead to problems with the impact sound during use and an incapability ofadapting to unevennesses of the underlying surface. The injection-moldedtile comprises coupling means along the edges, however, these do notprovide for a locking in vertical direction. Moreover, the precision ofinjection molding, in particular in the case of soft thermoplasticmaterials, is inferior. This method is time-consuming, and moreoverthere is little possibility of variation in the appearance of the wearside of the tiles. Such tiles possibly still show a strong dimensionalchange with changing temperature.

GB 1 248 060 describes, as an alternative of a method similar to that ofU.S. Pat. No. 6,306,318, the possibility of manufacturing reinforcedthermoplastic materials by means of a method wherein continuous fiberlayers are stacked and pressed in a mold alternating with thermoplasticgranulate layers. According to the examples, hard PVC can be applied asthermoplastic material. Above all, this document aims at an increasedbending stiffness of the obtained thermoplastic material. This method,too, is time-consuming and offers little possibility of variance in theappearance of the obtained materials.

The present invention relates to an alternative panel, which, in thefirst place, is intended as a floor panel for forming a floating floorcovering. According to various preferred embodiments of the invention,also a solution is offered for one or more problems with the panels ofthe state of the art.

To this aim, the invention, according to its first independent aspect,relates to a panel for forming a floor covering, wherein this panelcomprises at least two layers consisting of thermoplastic material, withthe characteristic that the aforementioned two layers substantiallyconsist of a strewn and pressed granulate, wherein the respective layersenclose a glass fiber layer, preferably a glass fiber fleece. As layersof strewn apart and pressed granulate of the respective thermoplasticmaterial are used, wherein these layers enclose a glass fiber layer, abetter stability of the panels is obtained. In this manner, the glassfiber layer is better embedded in the panel and in this manner cancounteract dimensional changes more effectively.

Preferably, the glass fiber layer relates to a glass fiber cloth orglass fiber fleece. Preferably, this relates to a so-called “non-woven”,namely a glass fiber fleece. The inventors have found that with a glassfiber fleece, better embedding in the thermoplastic material and therebya more effective working thereof can be achieved.

Preferably, said glass fiber layer is covered with an adherence layer,for example, in that the glass fiber layer has been impregnated in saidthermoplastic material of the granulate, or in that it is provided witha coating layer of this thermoplastic material.

Preferably, at least one of said two layers, and still better bothlayers, comprise individual fibers, for example, of a length greaterthan 1 mm. By “individual fibers”, it is meant that they as such do notform part of a layer or a pre-fabricated layer, such as a glass fibercloth, but, for example, are distributed freely within the thermoplasticmaterial, whether or not uniformly. The inventors have found that theuse of such loose or individual fibers further can contribute to thedimensional stability of the panels, and then in particular can restrictthe extent of expansion or shrinkage. Such individual fibers can beactive over a greater thickness of the thermoplastic material than theaforementioned glass fiber fleece (non-woven) or glass fiber cloth(woven). Such individual fibers further preferably also show one or moreof the following features, namely that:

-   -   they have an average length of 3 millimeters or more. Good        results have been obtained with fibers having an average length        of approximately 4.5 millimeters. Preferably, the average length        is shorter than 10 millimeters or even shorter than 6        millimeters;    -   they are present in the layer in a concentration situated        between 1 and 25 percent by weight, and still better between 5        and 15 percent by weight, without including possible other        fillers, such as chalk;    -   this relates to individual glass fibers. Preferably, E-Glass is        chosen, for example, as defined in DIN 1259. According to an        alternative, steel fibers or other fibers, such as carbon        fibers, aramid fibers or polyethylene fibers can be applied;    -   this relates to moisture-resistant fibers and, thus, no        cellulose fibers, unless they are coated or treated, for        example, by means of acetylation, in order to render them, at        least to a certain extent, moisture-resistant;    -   the fibers, for example, glass fibers, on average have a        diameter situated between 1 and 100 micrometers or still better        between 3 and 30 micrometers, wherein in various experiments the        range between 5 and 25 micrometers has proven to be the best;    -   the fibers are provided with a coating or a treatment which        improves the adherence to the thermoplastic material.        Preferably, the surface of the fibers is treated with a coupling        agent, such as with silane;    -   the fibers have a thermal expansion coefficient which is smaller        than that of the thermoplastic material in which they are        situated, and/or a Young's modulus which is higher than that of        the thermoplastic material in which they are situated;    -   the fibers have a Young's modulus of more than 40, still better        of more than 60 GPa;    -   the fibers have a thermal expansion coefficient of less than 30        μm/mK and still better of less than 5 μm/mK.

Preferably, said thermoplastic material relates to polyvinyl chloride,preferably semi-rigid or even soft polyvinyl chloride (PVC), namely PVCwith plasticizers, for example, with a percentage of plasticizers in thePVC of more than 12, more than 20 or even more than 30 percent byweight. It is clear that instead of using PVC, it is also possible toapply polypropylene (PP), polyethylene (PET) or polyurethane (PUR).

Preferably, the panel of the invention also comprises, above said twolayers, at least a printed decor and a translucent or transparent wearlayer provided there above.

Said decor can consist of a print performed on a synthetic materialfilm, for example, a printed PVC film, PU film, PP film, PET film. Inthe case of a PP film, this may relate, for example, to an orientedpolypropylene film. In the case of a PVC film, this preferably relatesto a hard PVC film, namely, to a film on the basis of PVC withoutplasticizer or with an amount of plasticizer of less than 5 percent byweight. Such hard PVC film can be printed with higher precision,certainly in the case of a print performed with water-based inks. Insuch case, in a drying operation by means of supplied heat in the dryingprocess is desirable, however, the possible expansion of the film isrestricted as a result of choosing hard PVC. The wear layer preferablyalso comprises a thermoplastic material, such as soft or hard PVC, PU,PP or PET. Preferably, the transparent thermoplastic wear layer is freefrom solid additives, such as ceramic particles for enhancing wearresistance, although this kind of particles, as such is not excluded.However, the inventor has found that they can be omitted with the aim ofobtaining good transparency while still maintaining an acceptable wearresistance, namely a wear resistance comparable to or better than thatof a laminate panel of the AC2 or AC3 class, as measured according to EN13329. The wear layer preferably has a thickness of minimum 0.15millimeters and still better minimum 0.3 millimeters, however,preferably less than 1 millimeter, wherein 0.2 to 0.4 millimeters is agood value. With this good value, by means of the thermoplastic materialof the wear layer alone, thus, without taking into account possiblesolid additives, already a sufficient wear resistance can be obtainedfor residential applications. So, for example, it is possible to achievean IP value (initial wear point) of 2000 or more in the Taber tests, asdescribed in EN 13329, annex E.

According to an alternative, it is not excluded that the printed decoror the print might be provided on the underside of the wear layer.

Preferably, the aforementioned two layers which according to theinvention enclose the glass fiber layer relate to a substrate layer,namely a layer which extends underneath a top layer. Preferably, atleast one of these layers is situated at least halfway in the thicknessof the panel. In this manner, the risk of a possible bending effect withchanging temperature is restricted even further or is excluded.

Preferably, the thickness of the panel substantially, thus, for morethan one half of it or more, is formed by the aforementioned two layerswhich enclose the glass fiber layer. Preferably, the thickness of thepanel essentially, namely, for more than 80 percent thereof, is formedby these two layers.

Preferably, the substrate has a thickness of 1.3 to 10 millimeters. Theentire floor panel preferably has a thickness situated between 2 and 6millimeters. Preferably, the substrate forms at least one half of thethickness of the floor panel.

On the underside of the substrate, a counter layer or underlay, such asa vapor-tight layer, can be provided. Such counter layer or underlaypreferably consists of a thermoplastic synthetic material layer. Thecounter layer preferably has a thickness which corresponds to thethickness of the top layer, including a possible backing layer, however,preferably is made thinner. The counter layer preferably functions as abalancing layer, such that a balanced sandwich structure can beobtained, namely without or only with minimal warping of the panels.

According to the most preferred embodiment of the invention, the panelis free from such aforementioned counter layer or underlay. In suchcase, the lowermost of said two layers, which, according to theinvention, enclose the glass fiber layer, preferably also forms theunderside of the panel.

Preferably, said thermoplastic material of at least one of said twolayers which, according to the invention, enclose the glass fiber layer,further also comprises fillers, such as chalk or limestone.

A lacquer layer can be applied as the uppermost layer of the panel.Herein, this may relate to a UV- or electron beam-hardening lacquerlayer and/or to a PU lacquer layer.

Preferably, the invention is applied with floor panels which, at therespective edges, are provided with mechanical coupling means allowingto couple two of such floor panels to each other in such a manner that alocking is created in a vertical direction perpendicular to the plane ofthe coupled panels, as well as in a horizontal direction perpendicularto the coupled edge and in the plane of the panels. Preferably, thecoupling means also show one or a combination of two or more of thefollowing features:

-   -   the feature that the mechanical coupling means or coupling parts        are substantially realized as a tongue and a groove bordered by        an upper lip and a lower lip, wherein this tongue and groove        substantially are responsible for the locking in said vertical        direction, and wherein the tongue and the groove are provided        with additional locking parts, substantially responsible for the        locking in said horizontal direction. Preferably, the locking        parts comprise a protrusion on the lower side of the tongue and        a recess in the lowermost groove lip. Such coupling means and        locking parts are known, for example, from WO 97/47834;    -   the feature that the mechanical coupling means or coupling parts        press the coupled floor panels against each other, for example,        in that these mechanical coupling means are provided with a        so-called pre-tension, as known as such from EP 1 026 341. The        tensioning force with which the floor panels are pressed against        each other or towards each other, can be obtained, for example,        in combination with the above feature by means of a lower lip,        which is bent out in coupled position and which, when trying to        spring back, presses against the lower side of the tongue;    -   the feature that the mechanical coupling means allow a coupling        by means of a horizontal, or quasi-horizontal shifting movement        of the panels towards each other;    -   the feature that the mechanical coupling means allow a coupling        by means of a turning movement W along the respective edges;    -   the feature that the mechanical coupling means allow a coupling        by means of a downward-directed movement of a male coupling part        having, for example, a tongue, up into a female coupling part        having, for example, a groove. With this type of panels, there        is a high risk that the connection will get released with an        expansion or pressing upward of the panels, as in such case the        locking in vertical direction can be weak;    -   the feature that the mechanical coupling means, or at least the        pertaining upper edge, are realized by means of a milling        operation with rotating milling tools.

Preferably, said coupling means substantially are realized in saidsubstrate, more particularly at least in at least one of theaforementioned two layers which, according to the invention, enclose theglass fiber layer. Preferably, said coupling means are provided by meansof a milling operation with rotating milling tools. Preferably, thefloor panel of the invention relates to a rectangular, either oblong orsquare, panel, which is provided with mechanical coupling means on bothpairs of opposite edges.

Panels which are provided with coupling means preferably have athickness of at least 2.5, still better at least 3 millimeters. In thesepanels, the invention shows its advantages to the full, as the increasedstability which can be offered by the provisions of the invention canresult in a qualitatively better coupling of the panels, wherein thisquality can also be maintained longer.

It is not excluded that the invention is applied for panels which arefree from coupling means at their edges, wherein these panels then areintended for being glued to the underlying surface with their lowerside. Such panels preferably have a thickness of less than 4millimeters, however, preferably of more than 1.5 millimeters.

The panels of the invention preferably have a width of 8 centimeters ormore. Particularly preferred dimensions are a width situated between 14and 22 centimeters and a length situated between 118 and 220centimeters. It is clear that here, this relates to panel-shapedelements and thus not to wall-to-wall floor covering. However, thepanel-shaped elements do not necessarily have to be rigid, but can berollable. In particular, the invention relates to so-called LVT (luxuryvinyl tile) in plank format or in tile format.

According to an independent second aspect, the invention also relates toa method which can be applied for manufacturing panels with thecharacteristics of the first aspect or the preferred embodimentsthereof, however, which can also be applied more widely. To this aim,the invention relates to a method for manufacturing panels, wherein saidmethod comprises at least the step of forming a first layer and a secondlayer of thermoplastic material, with the characteristic that forforming said first layer, a granulate of said thermoplastic material isdeposited on an underlying surface, a glass fiber layer, preferably aglass fiber fleece, is provided on this deposited layer of granulate,and thereafter, for forming said second layer, also a granulate of saidthermoplastic material is deposited on said glass fiber layer, whereinin a subsequent step both layers, namely, said first as well as saidsecond layer, including the glass fiber layer, are consolidated. Whenproviding the glass fiber layer and the granulate of the second layer,the granulate of the first layer thus is not yet consolidated, or, inother words, at that moment the first layer still consists of loose,strewn granulate. As the two layers, including the glass fiber layer,are consolidated together, a better inclusion of the glass fiber layeris obtained. Said consolidation preferably is performed in a heatedpress device, such as between the belts of a continuous press device.

According to the second aspect, the two layers concerned are formed onthe basis of a granulate of said thermoplastic material. For example,the granulate initially can be strewn or deposited on an underlyingsurface in another manner, after which this granulate is consolidated toa thermoplastic layer by means of a, preferably heated, press treatment.According to the most preferred embodiment, the granulate of the firstlayer is deposited, or possibly strewn, on a transport device, afterwhich the glass fiber layer, preferably coming frojn a roll, is placedon the strewn layer, and after which the granulate of the second layeris deposited. Then, the two strewn layers enclosing the glass fiberlayer are guided between the belts of a continuous pressing device,where consolidating is performed or at least is initiated. Preferably,the strewing and pressing thus is performed in a continuous manner andin line with each other. According to the present particular preferredembodiment, to this aim a device can be applied, such as the one knownfrom WO 2012/016916, however, with at least two strewing units, namely,at least one for each of said two layers.

It is clear that preferably soft PVC, namely PVC having an amount ofplasticizer of 12 percent by weight or more, is applied as athermoplastic material and that preferably at least one, however, stillbetter both of said two layers further also comprise fillers, such aschalk or lime. These fillers either can be supplied via the granulateconcerned or not. Preferably, the granules of said granulate, in thefirst as well as in the second layer, for at least 50 percent by weightor for 60 to 80 percent by weight consist of fillers, such as chalk orlime. By applying highly filled granulate, a better distribution of thefillers in the layer to be realized, as well as a smooth productionprocess are obtained.

Preferably, the granulate, of the first as well as of the second layer,has an average particle size of 1 to 3 millimeters or of approximately 2millimeters or less. According to a particular embodiment, at least inone of said two layers a so-called micro granulate is applied, orgranulate having an average particle size of less than 1 millimeter,such as, for example, a granulate having an average particle size ofapproximately 800 micrometers. By making use of micro granulate, a moreuniform composition of the respective thermoplastic layer is obtained.Hereby, the glass fiber layer will be better enclosed by said twolayers.

Preferably, said granulates also comprise individual fibers, preferablyglass fibers.

It is evident that the obtained consolidated whole of said two layersand the enclosed glass fiber layer must be processed together with othermaterial, whether or not in layers, for forming the final panel.

According to the invention, it is possible that in the first placeplates or sheets are obtained, from which a plurality of such panels isobtained by subdividing them.

Processing the consolidated assembly of the two layers with enclosedglass fiber layer generally can be performed in various manners.According to a first possibility, by means of heat and pressure therespective layer, at least at the surface, is melted together with oneor more further thermoplastic layers, such as a printed decor filmand/or a wear layer and/or a further substrate layer. According to asecond possibility, the material of one or more further layers, inparticular one or more further substrate layers, is provided in liquidform or in paste form by calendering it or providing it on the alreadyformed layer in another manner.

Preferably, the method of the invention also comprises the steps ofproviding a printed decor and a translucent or transparent wear layer onsaid two layers, whereby these steps are performed after havingconsolidated said two layers, including the glass fiber layer. At leastin the step of providing said wear layer, it can be started from athermoplastic film, which is connected to the consolidated assembly ofsaid two layers enclosing the glass fiber layer by means of a thermallaminating process. Preferably, to this aim also a continuous pressdevice is applied, and preferably these steps are performed in line withthe steps of forming the first and/or the second layer.

It is noted that the transparent or translucent wear layer, whenapplied, preferably is free from fibers, whether or not in the form oflayers. When use is made of a decor film, this latter, too, preferablyis free from fibers, whether or not in the form of layers. For the decorfilm, preferably a printed hard PVC film is applied, namely, a PVC filmwhich is free or almost free from plasticizers. As aforementioned, theuse of a hard PVC film leads to a print of a higher quality, as it isless subject to dimensional changes during printing. This isparticularly advantageous when during printing one or more dryingtreatments by means of heat supply are performed, as may be the casewhen printing with water-based pigmented inks. For the transparent wearlayer, use can be made of a soft PVC layer, for example, with an amountof plasticizers of 12 percent by weight or more.

Prior to said steps of providing a printed decor and the translucent ortransparent layer, preferably a levelling treatment is performed on thesurface of said two layers. The levelling treatment may consist of agrinding treatment and/or of providing one or more layers of plastisol.Preferably, this levelling treatment is performed in line with the stepsof forming the first and/or the second layer.

It is evident that the thermoplastic material further can have thecompositions stated in the context of the first aspect. Preferably, thethermoplastic material relates to a feedstock for forming semi-rigid orsoft PVC. Preferably, this PVC comprises an amount of plasticizer ofmore than 12 percent by weight, for example, of 20 percent by weight ormore.

Further, it is clear that the granulate which is applied for said firstlayer does not necessarily have to be identical to the granulate whichis applied for said second layer. By applying granulates of mutuallydiffering composition and/or average particle size, particular featurescan be attained.

The above finding of course is advantageous, independent of the factwhether or not an enclosed glass fiber layer is applied. Therefore, theinvention, according to an independent third aspect, also relates to amethod for manufacturing panels, wherein this method comprises at leastthe step of forming a first layer and a second layer of thermoplasticmaterial, with the characteristic that for forming said first layer, afirst granulate of said thermoplastic material is strewn and thereafter,for forming the second layer, a second granulate of said thermoplasticmaterial is strewn on top of said first layer, wherein in a subsequentstep both layers are consolidated and wherein the composition and/or theaverage particle size of the first granulate is different in comparisonwith the second granulate.

The invention of the third aspect can be performed in various possiblemanners. Below, without desiring to be exhaustive, some possibilitiesare summed up.

According to a first possibility, the granulates comprise a differentamount of plasticizer, wherein one of the granulates comprises 12percent by weight or more of plasticizer and the other of the granulatescomprises less than 5 percent by weight or no plasticizer. According tothis first possibility, the granulate preferably relates to a granulateon the basis of PVC (polyvinyl chloride), wherein one of the granulatesthus comprises soft PVC, whereas the other granulate comprises hard orsemi-rigid PVC.

According to a first practical embodiment of this first possibility, thelayer formed by the soft PVC is situated closer to the underside of thepanel than the layer formed by the hard or semi-rigid PVC. By means ofthis first practical embodiment, a floor panel can be obtained which canadapt to possible unevennesses on the underlying surface by means of thesoft PVC, whereas the risk that this unevenness migrates to, or showson, the surface of the panel is strongly reduced by means of theintermediate layer of hard or semi-rigid PVC. The layer of hard orsemi-rigid PVC can be made thinner than the layer of soft PVC. Above thelayer of hard or semi-rigid PVC, a further strewn layer of granulate onthe basis of soft PVC can be situated, such that the layer of hard PVCis located approximately in the middle of the substrate.

According to a second practical embodiment of this first possibility,the layer formed by the hard or semi-rigid PVC is situated closer to theunderside of the panel than the layer formed by the soft PVC. By suchconstruction, the bending stiffness of the final panel can be increased.Preferably, a second layer of the hard PVC granulate is situated on theother side of the layer formed by the soft PVC, such that a stablesandwich structure is created. Preferably, the substrate of the panelsubstantially consists of three layers, namely a lowermost layer on thebasis of hard PVC, a central layer on the basis of soft PVC, and anuppermost layer on the basis of hard PVC. Of course, the substrate cancomprise an underlay on the underside, and on the upper side a top layerwith a printed decor and a translucent or transparent wear layer. Thelayer or layers of hard or semi-rigid PVC can be made thinner than thecentral layer of soft PVC.

According to a second possibility, the granulates have a differentaverage particle size, wherein one of the granulates has an averageparticle size of 1.5 to 2.5 millimeters and the other of the granulateshas an average particle size of less than 1 millimeter. The granulatehaving an average particle size of less than 1 millimeter preferably isapplied for forming an outermost layer of the substrate, for example,for a layer on which the printed decor is provided, whereas the largergranulate can be applied for forming a central layer situated thereunderneath. Hereby, a uniform surface is obtained on which the decor canbe provided in a simple manner and without visible defects.

According to a third possibility, the granulates have a differentcomposition in that one of the granulates is obtained from freshpolyvinyl chloride and the other is obtained from a recyclate ofpolyvinyl chloride. Preferably, the granulate of fresh polyvinylchloride is situated at the exterior of the substrate, whereas thegranulate on the basis of the recyclate is applied for an internal orcentral layer situated there beneath. According to this possibility, itis also possible to obtain a uniform surface on which the decor can beprovided in a simple manner and without visible defects.

According to a fourth possibility, the granulates have a differentcomposition in that one of the granulates comprises 60 to 80 percent byweight of filler, such as chalk, and the other comprises less than 50percent by weight of filler, or no filler. The highly filled layer canbe applied, for example, towards the underside of the panel in order toobtain an increased sound insulation, whereas the less filled or notfilled layer is situated there above. This latter layer realizes asurface layer with an acceptable uniformity on which the decor can beprovided in a simple manner and without visible defects.

It is evident that the invention also relates to panels which areobtained by means of a method with the characteristics of the thirdaspect.

It is clear that, according to the invention, by “substrate” an innerlayer of the floor panel itself is meant, which as such can be made one-or multi-layered, however, wherein the respective layer or layerspreferably have a common thickness which is larger than one half of thethickness of the entire panel concerned and/or wherein the respectivelayer or layers have a common weight which preferably is higher than onehalf of the weight of the entire panel concerned. Preferably, thecontour of the possible coupling means is substantially or entirelyrealized in the substrate.

Further, it is clear that by “fibers”, elongate particles are meant.Preferably, the length of such fiber is at least hundred times theaverage diameter thereof. Preferably, this relates to fibers with acircular or approximately circular cross-section.

With the intention of better showing the characteristics of theinvention, hereafter, as an example without any limitative character,some preferred embodiments are described, with reference to theaccompanying drawings, wherein:

FIG. 1 represents a panel with the characteristics of the invention;

FIG. 2, at a larger scale, represents a cross-section according to linesII-II in FIG. 1;

FIG. 3 schematically represents some steps in a method with thecharacteristics of the second aspect; and

FIG. 4, in a view similar to that of FIG. 2, represents another variant,obtained by means of a method with the characteristics of the thirdaspect.

FIG. 1 represents a rectangular and oblong floor panel 1 with a pair oflong sides 2-3 and a pair of short sides 4-5.

FIG. 2 represents that the respective floor panel 1 is composed ofvarious layers 6-7-8-9A-9B-10.

The substrate 11 is formed by the layers 9A and 9B of thermoplasticmaterial, in this case soft PVC, which substantially consist of strewnand pressed granulate. Further, the substrate layer 9 concernedcomprises an enclosed glass fiber fleece 12. Above the respective layers9A-9B, a top layer 13 is provided, which as such comprises a printeddecor film 7 and a transparent wear layer 6 on the basis ofthermoplastic material. The top layer 13 further also comprises abacking layer 8 located underneath the decor film 7. In the example, thebacking layer 8, the decor film 7 and the wear layer 6 are made on thebasis of polyvinyl chloride.

In the example, the decor film 7 is provided with a print with a woodpattern 14, wherein, per panel 1, each time the image of a single woodenboard is provided.

On the lower side 15 of the substrate 11, a counter layer 10 isprovided, which is also based on soft PVC. According to the invention,it is also possible that one of said two layers 9A-9B, namely thelowermost layer 9B, forms the lower side of the panel.

FIG. 2 represents that at least one of the layers 9A-9B is present atleast in the middle of the thickness T of the substrate 11. In thiscase, the respective layers 9A-9B and the enclosed glass fiber. layer 12form the entire substrate 11.

FIG. 2 further also represents that the respective layers 9A-9Bconstitute at least 40 percent and here even more than one half of thethickness T of the panel 1.

Further, the panel 1 of the example is provided with mechanical couplingmeans or coupling parts 16 on both opposite edges 2-3. FIG. 2 shows thatat least the mechanical coupling means 16 on the long pair of edges 2-3allow that two of such floor panels 1 can be coupled to each other insuch a manner that a locking is created in a vertical direction V1perpendicular to the plane of the coupled panels 1, as well as in ahorizontal direction H1 perpendicular to the coupled edges 2-3 and inthe plane of the panels 1. The illustrated coupling means 16 show thecharacteristic that they are substantially realized as a tongue 17 and agroove 18 bordered by an upper lip 19 and a lower lip 20, wherein saidtongue 17 and groove 18 substantially are responsible for the locking insaid vertical direction V1, and wherein the tongue 17 and the groove 18are provided with additional locking parts 21-22 substantiallyresponsible for the locking in said horizontal direction H1. In thiscase, the locking parts comprise a protrusion 21 on the lower side ofthe tongue 17 and a cooperating-therewith recess 22 in the lower lip 20.

The coupling means 16 represented here allow at least a coupling bymeans of a turning movement W along the respective edges 2-3.

The mechanical coupling means 16 are substantially realized in thelayers 9A-9B, which, according to the invention, enclose the glass fiberlayer. In the example, they are provided by means of a millingtreatment, for example, by means of rotating tools.

FIG. 3 represents some steps of a method for manufacturing the panel ofFIGS. 1 and 2. More particularly, the step is represented of forming thelayers 9A-9B with thermoplastic material, which, according to theinvention, enclose the glass fiber layer 12.

In the example of FIG. 3, the respective layers 9A-9B are formed on thebasis of a granulate 23 of the respective thermoplastic material.

FIG. 3 represents that the granulate 23 of the first layer 9B as well asof the second layer 9A initially is deposited on a transport device 25,on the glass fiber layer 12, respectively, by means of a strewing device24, after which it is consolidated between the belts 26 of a continuouspressing device 17. Herein, the granulate 23 is transported along one ormore heating devices 28 and possibly it can be cooled again after thepress treatment or at the end of the press treatment. By cooling, it isachieved that the pressed plates, sheets or layers relatively fast aremanageable for further processing.

FIG. 3 further also represents that simultaneously with pressing, afurther layer, in this case at least the decor film 7, can be applied orinserted by providing it on the granulate 23 in the press treatment.Instead of to a decor film, this may also relate, for example, to anadditional glass fiber layer 12 or to a backing layer 8, or a wear layer6. It may also relate to a composition of layers already laminatedtogether, such as an already entirely or partially composed top layer 3,which, for example, comprises at least a decor film 7 and a wear layer6, or at least a backing layer 8 and a decor film 7; or the backinglayer 8, decor film 7 as well as the wear layer 6. A possiblesuperficial lacquer layer preferably is provided after the presstreatment. This is not represented here.

Although FIG. 3 represents only two strewing devices 24, of course alsofurther strewing devices, for example, a third and a fourth strewingdevice, can be provided. Further, it is clear that these strewingdevices 24 can deposit granulates 23 of a mutually differing compositionand/or average particle size. In such case, an embodiment of the thirdaspect mentioned in the introduction is obtained.

FIG. 4 represents another example of a panel which is obtained by meansof a method with the characteristics of the third aspect, wherein thesubstrate 11 is obtained on the basis of at least two granulates 23having a mutually differing composition and/or average particle size. Inthe example, the layers 9B and 9C are formed on the basis of a granulatecomprising PVC with at least 12 percent by weight of plasticizer,whereas the layer 9A, situated centrally in the substrate, is formed onthe basis of a granulate comprising PVC with less than 5 percent byweight of plasticizer or without plasticizer. FIG. 4 thus forms anexample of the first practical embodiment, mentioned in theintroduction, of the first possibility within the third aspect. FIG. 4also shows that the layer 9A can be made thinner than the layers 9A and9C. In this case, the layer 9A on the basis of the hard or semi-rigidPVC has a thickness T2 which is less than 20 percent of the overallthickness T1 of the substrate 11. This embodiment may lead to asignificant reduction of the emerging or showing of any unevenness inthe underlying surface towards the decorative side of the floor panel 1.

The present invention is in no way limited to the herein above-describedembodiments; on the contrary, such panels, methods and granulates can berealized according to various variants, without leaving the scope of thepresent invention. Moreover, the panels, instead of as floor panels, canalso be realized as wall panels or ceiling panels or even as furniturepanels.

1-9. (canceled)
 10. A method for manufacturing panels, said panel havinga substrate at least comprising a first substrate layer and a secondsubstrate layer enclosing a glass fiber layer, wherein said methodcomprises at least the steps of: forming a first substrate layer ofthermoplastic material and a second substrate layer of thermoplasticmaterial, wherein for forming said first substrate layer, a granulate ofsaid thermoplastic material is strewn, a glass fiber layer in the formof a non-woven glass fiber fleece or a woven glass fiber cloth isprovided on this strewn layer, and thereafter, for forming said secondsubstrate layer, also a granulate of said thermoplastic material isstrewn on said glass fiber layer, wherein in a subsequent step bothsubstrate layers, including the glass fiber layer, are consolidatedbetween belts of a continuous pressing device, and wherein thethermoplastic material is polyvinyl chloride having a plasticizercontent of more than 12 percent by weight, and providing a printed decorand a translucent or transparent wear layer on said two substratelayers, wherein these steps are performed after having consolidated saidfirst substrate layer and the second substrate layer, including theglass fiber layer, wherein said translucent or transparent wear layer isprovided above the printed decor, is based on thermoplastic material,and has a minimum thickness of 0.15 millimeters.
 11. The method of claim10, wherein said granulates also comprise individual glass fibers. 12.The method of claim 10, wherein at least for the step of providing saidwear-layer, it is started from a thermoplastic film, which is connectedto the consolidated assembly of said two layers by means of thermallamination.
 13. The method of claim 10, wherein said granulate of thefirst layer and/or the second layer shows an average particle size of 2millimeters or less.
 14. The method of claim 10, wherein said granulatecomprises at least 50 percent by weight of fillers.
 15. The method ofclaim 10, wherein for forming said first layer, a first granulate ofsaid thermoplastic material is strewn and thereafter, for forming thesecond layer, a second granulate of said thermoplastic material isstrewn on top of said first layer, wherein in a subsequent step bothlayers are consolidated and wherein the composition and/or the averageparticle size of the first granulate is different in comparison with thesecond granulate.
 16. The method of claim 15, wherein the firstgranulate differs from the second granulate in one or in a combinationof two or more of the following features: the granulates comprise adifferent amount of plasticizer, wherein one of the granulates comprises12 percent by weight or more of plasticizer and the other of thegranulates comprises less than 5 percent by weight or no plasticizer;the granulates have a different average particle size, wherein one ofthe granulates has an average particle size of 1.5 to 2.5 millimetersand the other of the granulates has an average particle size of lessthan 1 millimeter; the granulates have a different composition in thatone of the granulates is obtained from fresh polyvinyl chloride and theother is obtained from a recyclate of polyvinyl chloride; the granulateshave a different composition in that one of the granulates comprises 60to 80 percent by weight of filler, such as chalk, and the othercomprises less than 50 percent by weight of filler, or no filler. 17.The panel obtained according to a method with the characteristics ofclaim 10, wherein this panel comprises at least two layers ofthermoplastic material and wherein said two layers substantially consistof a strewn and pressed granulate, wherein the respective layers enclosea glass fiber layer and/or wherein said two layers are formed ofgranulate having a mutually differing composition and/or mutuallydiffering average particle size.
 18. The method of claim 10, whereinsaid printed decor is provided on a synthetic material film.
 19. Themethod of claim 10, wherein said method further comprises the step ofmilling profiled edges to said first and second substrate layer, whereinsaid profiled edges comprise mechanical coupling means substantiallyshaped as a tongue and a groove, wherein said groove is limited by anupper lip and a lower lip.
 20. The method of claim 10, wherein saidmethod further comprises the step of levelling the surface of at leastone of said two substrate layers prior to the step of providing saidprinted decor.
 21. A method for manufacturing panels, said panel havinga substrate at least comprising a first substrate layer and a secondsubstrate layer enclosing a glass fiber layer, wherein said methodcomprises at least the steps of: forming a first substrate layer ofthermoplastic material and a second substrate layer of thermoplasticmaterial, wherein for forming said first substrate layer, a granulate ofsaid thermoplastic material is strewn, a glass fiber layer in the formof a non-woven glass fiber fleece or a woven glass fiber cloth isprovided on this strewn layer, and thereafter, for forming said secondsubstrate layer, also a granulate of said thermoplastic material isstrewn on said glass fiber layer, wherein in a subsequent step bothsubstrate layers, including the glass fiber layer, are consolidatedbetween belts of a continuous pressing device, and wherein thethermoplastic material is polyvinyl chloride having a plasticizercontent of more than 12 percent by weight, and providing a printed decorand a translucent or transparent wear layer on said two substratelayers, wherein these steps are performed after having consolidated saidfirst substrate layer and the second substrate layer, including theglass fiber layer, wherein said translucent or transparent wear layer isprovided above the printed decor, is based on thermoplastic material,and has a minimum thickness of 0.15 millimeters, and wherein at leastone of the first substrate layer, the second substrate layer, or theglass fiber layer is at least situated in a middle of the thickness ofthe substrate.
 22. The panel according to claim 21, wherein the glassfiber layer is a glass fiber fleece.
 23. The method of claim 21, whereinsaid printed decor is provided on a synthetic material film.
 24. Themethod of claim 23, wherein said synthetic material film is a film onthe basis of polyvinylchloride with a plasticizer content of less than 5percent by weight.
 25. The method of claim 23, wherein said syntheticmaterial film is a film chosen from the list consisting of Polyvinylchloride film, Polyurethane film, Polypropylene film, Polyethyleneterephthalate film.
 26. The method of claim 21, wherein said methodfurther comprises the step of milling profiled edges to said first andsecond substrate layer, wherein said profiled edges comprise mechanicalcoupling means substantially shaped as a tongue and a groove, whereinsaid groove is limited by an upper lip and a lower lip.
 27. The methodof claim 21, wherein said method further comprises the step of levellingthe surface of at least one of said two substrate layers prior to thestep of providing said printed decor.
 28. A method for manufacturingpanels, said panel having a substrate at least comprising a firstsubstrate layer and a second substrate layer enclosing a glass fiberlayer, wherein said method comprises at least the steps of: forming afirst substrate layer of thermoplastic material and a second substratelayer of thermoplastic material, wherein for forming said firstsubstrate layer, a granulate of said thermoplastic material is strewn, aglass fiber layer in the form of a non-woven glass fiber fleece or awoven glass fiber cloth is provided on this strewn layer, andthereafter, for forming said second substrate layer, also a granulate ofsaid thermoplastic material is strewn on said glass fiber layer, whereinin a subsequent step both substrate layers, including the glass fiberlayer, are consolidated between belts of a continuous pressing device,and wherein the thermoplastic material is polyvinyl chloride having aplasticizer content of more than 12 percent by weight, and providing aprinted decor and a translucent or transparent wear layer on said twosubstrate layers, wherein these steps are performed after havingconsolidated said first substrate layer and the second substrate layer,including the glass fiber layer, wherein said translucent or transparentwear layer is provided above the printed decor, is based onthermoplastic material, and has a minimum thickness of 0.15 millimeters,and wherein at least one of the first substrate layer, the secondsubstrate layer, or the glass fiber layer comprises a portion locatedhalfway the thickness of said substrate.